MAxxIMA SOLAR BATTERY
USER MANUAL
Recommended charging, equalization and preventive
maintenance procedures for Maxxima Batteries
Table of Contents
Manual ............................................................................................. 2
Equipment Needed .......................................................................... 2
Safe Handling Procedure ................................................................. 2
Inspection ........................................................................................ 2
Installation ....................................................................................... 2
Battery Orientation .................................................................... 2
Cable Sizing ............................................................................. 2
Parallel/Series Connections. ...................................................... 3
Activation of a Dry Battery ............................................................... 4
............................................................................. 4
Activation of a Wet Battery .............................................................. 5
Cleaning .......................................................................................... 5
Initial Charge of Wet Batteries ......................................................... 5
Initial Charge ................................................................................... 6
Bulk Charge.............................................................................. 7
Absorption Charge .................................................................... 7
Float Charge. ............................................................................ 8
Equalization. ............................................................................. 8
Frequency ................................................................................ 8
Method ............................................................................................. 8
Temperature Probe ................................................................... 9
Cleaning. .................................................................................10
Pulse Charging ........................................................................10
Battery Additives. .....................................................................10
Storage Procedure ......................................................................... 10
Spillage Procedure ........................................................................ 10
Disposal Procedure ....................................................................... 11
Quick Checklist.............................................................................. 11
Warranty ........................................................................................ 11
Lead Acid Battery Glossary ........................................................... 15
Contacts ........................................................................................ 17
Battery Charging
MANUAL
Marathon Batteries has been manufacturing deep cycle lead-acid batteries since 2009.
Experience gained has helped us achieve an unmatched reputation along with specific
measures to obtain the maximum performance and life from our product.
This manual describes the recommended charging, equalization and preventive
maintenance procedures for Marathon batteries in order to maximize battery life.
Equipment Needed
• Goggles, rubber gloves and rubber boots
• Distilled water
• Baking soda
• Voltmeter
• Hydrometer
• Battery charger
Safe Handling Procedure
Always wear acid-resistant clothing, PVC gloves, goggles and rubber boots –
especially where there is risk of splashing. Always keep the batteries in an
upright position. Always have plenty of water available in case of acid spillage.
Inspection
Upon arrival, check the battery for visible damage (i.e. cracks, dents,
deformation and other visible abnormalities). Verify connections, assure that
they are clean. If the battery is dirty, or if any minor amount of acid has
spilled onto the case, check cleaning section. Any fluid on or around the
battery could indicate that the case is not properly sealed. Please verify the
polarity of the terminals. Please contact your retailer or Marathon Batteries
Private Limited to determine if the battery needs replacement.
Installation
Marathon offers batteries for a wide variety of applications. No matter the application,
always be certain that the battery is properly secured, free of contaminants and
that all connections are in good contact with the terminals. Contact your
retailer or MBPL for additional information.
Battery Orientation
Flooded lead acid batteries must be kept in an upright position at all
times. Electrolyte in the battery will spill if tilted.
Cable Sizing
The size of the cables used should be proportionate to the amount of
amperage in your system.
2
Parallel/Series Connections:
Certain applications demand more voltage or more capacity than one
battery’s output. By arranging the connection configuration, one is able to
increase the output voltage, output capacity or both if needed.
To increase voltage, connect the batteries in series as shown in Figure 1.
Example:
Battery Voltage = 12V each
Battery Capacity = 100 AH
each System Voltage = 24V
System Capacity = 100 AH
Figure 1
Voltage Increase
To increase capacity, connect the batteries in parallel as shown in Figure 2.
Example:
Figure 2
Battery Voltage = 12V each
Battery Capacity = 100 AH each
Capacity Increase
System Voltage = 12V
System Capacity = 200 AH
To increase capacity and voltage, connect the batteries in series parallel
as shown in Figure 3.
Example:
Battery Voltage = 12V each
Battery Capacity = 100 AH
each System Voltage = 24V
System Capacity = 200 AH
Figure 3
Voltage/Capacity Increase
Activation of a Dry Battery
Special order batteries can be shipped dry (acid shipped separately). To activate
these batteries, start by removing the vent caps. Using approved battery grade
electrolyte (1.210), fll each cell halfway between the plates and the bottom of the
vent well tube. (See Figure 4 on page 7.) It is important not to over fill the cells as
the acid will expand upon charging. If the cells are too full, the acid will spill out of
the top of the cells. Allow electrolyte to saturate into the plates and separators for
at least 90 minutes. The temperature of the electrolyte will rise and the specific
gravity will drop. Once this is complete, place the batteries on charge at the
fnishing rate (5% of the 10 or 20 hour rate). The rate may be increased if the
battery does not begin to gas. Do not let the cell temperature exceed 46° C. If the
temperature becomes excessive or the cells begin
to gas vigorously, reduce the rate of charge. Continue charging until the cell
(or cells) reaches within .005 points of the specific gravity of the filling
electrolyte corrected for 25° C. We recommend to continue charging for an
additional 60 minutes to insure no further rise in specific gravity.
Top up or remove electrolyte as necessary for proper level. Never add
electrolyte (only approved water) after activation. Replace vent caps and
remove any spillage of electrolyte. If necessary, clean with bicarbonate of
baking soda and water (100 grams of soda to one litre of water). Rinse with
water and wipe dry. Ensure that the soda solution does not get into cells.
*Do not place on charge until electrolyte temperature is below 35°C.
Battery Charging
Temperature/Volt per cell
Bulk/Absorption
Float
Equalization
0˚C to 16˚C
17˚C to 27˚C
28˚C to 40˚C
2.5 Volt
2.4 Volt
2.36 Volt
2.19
2.58-2.67
Example: 12V
(6 cells)
15.0 Volts
14.4 Volts
14.16 Volts
13.14 Volts
15.48-16.02 Volts
Table 2 – Charge parameters
NOTE: The most common type of charge method at present is the three stage plus equalization.
This outline is based on this type of charging method. Check with your charger manufacturer for
specific settings for their equipment. Please note, if “topping up” with water is required more than
once every two (2) months, the voltage settings are too high on your system.
4
Activating Instructions/Maintenance for a Wet Battery
Caution: Always wear the proper personal protective equipment
(goggles, gloves, clothing) when handling batteries and electrolytes
WARNING:
• WET BATTERIES MUST BE FULLY CHARGED BEFORE BEING
DELIVERED TO THE END USER. PLEASE REFER TO THE “INITIAL
CHARGE OF WET BATTERIES” SECTION OF THIS DOCUMENT.
• ADD DISTILLED WATER ONLY TO WET BATTERIES. UNLESS
INSTRUCTED BY MBPL TECHNICAL SUPPORT, NEVER ADD
MORE ACID TO THE BATTERIES AT ANY TIME.
• FAILURE TO DO SO WILL RESULT IN MALFUNCTION AND VOID
THE WARRANTY.
Cleaning
Batteries should be kept clean at all times, including storage or usage. If stored in
a dirty area, regular cleaning should be performed. Before doing so, ensure that
all the vent caps are tightly fastened. Using a solution of water and baking soda
(100g per litre), gently wipe the battery and terminals, then rinse with water.
Initial Charge of Wet Batteries
1. Inspect batteries for damage. Important: read warning label on
batteries before proceeding.
2.Wet batteries are not shipped fully charged. The first charge brings the battery
to an operational state. Before this charging process, the cell electrolyte level
should be checked. Make sure the electrolyte covers the plates. If this isn’t the
case, add distilled water until all the plates are submerged. It is important not to
over fill because the level will rise during the charge process.
3.Check for correct polarity. Attaching the positive and negative
voltmeter lead to the positive and negative battery terminal should give a
positive voltage reading. If it is negative, a reverse polarity condition
exists and you should contact your dealer or MBPL.
4. Place batteries on charge. Please see Table 2 – charge parameters for
requited charging settings. Do not let the cell temperature exceed 54 .
8°C. If the temperature becomes excessive or the cells begin to gas
vigorously, reduce the rate of charge. Continue charging until all cells
reach the SG of the filling acid. All cell voltages should be even.
5. See Initial Charge below.
Initial Charge
A battery may not be fully charged when received. The first charge brings the
battery to an operational state. Before this charging process, the cell
electrolyte level should be checked. Please ensure the electrolyte (liquid)
covers the plates. If this isn’t the case, add distilled water until all the plates
are just submerged. It is important not to over fill because the level will rise
during the charging process. Charge voltages are indicated in Table 2.
The electrolyte’s specific gravity is the most accurate measurement and
it is recommended to verify its value to determine if the cells are, in fact,
fully charged. The specific gravity should be constant for 3 hours for an
accurate full charge reading. Check the state of charge as related to
specific gravity. Initial charging may take 10 hours. Once the battery is
fully charged, verify the electrolyte level in the cell once more. The fluid
should be 1/4 – 1/2 inch below the vent tube on each cell as shown in
Figure 1. Carefully add distilled water to adjust the level if needed.
% Charge
100
75
50
25
0
Specific Gravity* (SG)
1.255 – 1.275
1.215 – 1.235
1.200 – 1.180
1.165 – 1.155
1.130 – 1.110
Table 3 – Specific Gravity vs State of Charge
*PLEASE NOTE: The specific gravity is dependent on the electrolyte temperature. These values are for
a temperature of 27°C (80°F). To adjust, add/subtract 0.003 for every 5°C (10°F) increase/decrease.
6
Caution: Do not add water
or electrolyte to cells
before initial charging.
Adjust electrolyte levels
only when cells are fully
charged. Please contact
us if you have any
questions or concerns.
Figure 4 – Electrolyte level
• Bulk Charge
The first part of the charging process is the bulk charge; this is when the maximum
amount of current flows into the battery bank until a desired voltage is reached. The
recommended maximum current is 15% of the AH Capacity of the battery bank
based on the 10 hour rate. A lower current can be used, but this will prolong the
charging time. Bulk charge voltage set points are outlined in Table 2.
• Absorption Charge
Arguably, the most important part of the charge cycle is the absorption
charge. Since the bulk charge only recharges the battery bank to an 80%
level, the absorption charge completes the charging cycle. Most chargers on
the market have a timer that allows the user to adjust the duration for the
required time to return the battery to full charge. In order to set the correct
time, a simple calculation is required. With the help of the 20 AH capacity,
you can figure out the remaining charge required for the battery bank.
As stated previously, the bulk charge brings the bank to an 80% charging level. The
remaining 20% of the capacity is a function of time and current. The charger will maintain
current level until the bulk set point has been reached, then the charger switches to the
absorption timer. The current levels start decreasing as the internal resistance in the
battery increases. Assume over the time of the absorption charge that 50% of your
maximum charge current will be available (this is factored into the equation).
***
Where:
t = 0.42* C/1
t = Absorption Charge Time
C = 10hr Rated Capacity
I = Charging Current
0.42 = (20%/50%) + 5%. 5% is added due to losses***
• Float Charge
The batteries require a certain amount of voltage in order to maintain full
charge when no load is applied. The power supply keeps the batteries at a
constant full state of charge. In order to prolong battery life, the float settings
on the power supply should be adjusted to the voltage indicated in Table 2.
• Equalization
Individual cells will vary slightly in specific gravity after a charging cycle.
Equalization or a “controlled overcharge” is required to bring each battery plate to
a fully charged condition. This will reduce stratification and sulfating, two
circumstances that shorten battery life. Equalization of the battery bank is
recommended every 60 to 180 days, depending on the usage of the individual
system. To equalize the cells, charge the batteries until the voltage elevates to
the “Equalization” voltage shown in Table 2. Charge parameters and maintain for
2 to 3 hours per bank. A constant SG for 30 minutes is a good indication of cell
equalization. It is recommended to water the battery cells halfway through the
equalization. This will assure the water is mixed with the electrolyte.
• Frequency
It is recommended to equalize the batteries before usage. Corrective equalization
needs to be performed if symptoms arise such as a constantly running generator
(low capacity) or the battery bank will “not hold a charge”. These symptoms are
typical of a heavily sulfated battery. If a battery is not being fully charged on a
regular basis or limited equalization is performed using a generator, sulfating will
occur from “deficit” cycling. This undercharge condition can take months before it
becomes a major and noticeable problem.
Method
Corrective Equalization can take a very long time depending on the
degree of sulfating.
1. If you have a recombination cap, remove during equalization.
2. Set the charging controls to the highest voltage allowable by the
charge controller (inverter). Temperature should be monitored very
closely and kept below 50ºC.
3. Charge at a low DC current (5 A per 100 AH of battery capacity). If grid
power is not available, use solar panels or a good DC source when
possible. At high voltages, charging with generator can be difficult and
hard on the inverter.
8
4. Once every hour, measure and record the specific gravity and
temperature of a test cell. If the temperature rises above 46ºC and
approaches 52ºC, remove the batteries from charge.
5. If severely sulfated, it may take many hours for the specific gravity to rise.
6. Once the specific gravity begins to rise, the bank voltage will most
likely drop, or the charging current will increase. The charging current
may need to be lowered if temperature approaches 46ºC. If the charge
controller was bypassed, it should now be used or put back in line.
7. Continue measuring the specifc gravity until 1.250 is reached.
8. Charge the batteries for another 2 to 3 hours. Add water to maintain
the electrolyte above the plates.
9.Allow bank to cool and check and record the specific gravity of each cell. The
gravities should be 1.250 ± 0.005 or lower. Check the cell electrolyte levels
and add water if necessary.
It is recommended that a specific gravity reading of one pilot cell is measured and
recorded on a regular basis when it is thought that the bank is fully charged. The
measurement should be compared to previous readings. If the measurement is
lower than the previous reading, a longer absorption time and/or higher voltage
setting should be used. The longer the absorption time and the higher the bulk
voltage, the more water will be consumed but less equalization will be required.
Note: The specific gravity should rise as the cells use water. Look for trends in the
specific gravity over a period of time and make small adjustments as necessary.
For additional data and safety, many people choose to install
temperature probes inside the battery banks. Regardless of the size of
the battery bank, the probe should be installed on the side of one battery,
below the liquid level on a battery placed in the center of the bank. The
main factor to look for is maximum temperature. The battery bank should
not exceed an operating temperature of 50ºC.
• Cleaning
Batteries should be kept clean at all times. If stored in a dirty area, regular cleaning should be performed. Before doing so, assure that all the vent caps are tightly
fastened. Using a solution of water and baking soda (100g per litre), gently wipe
the battery and terminals with a damp sponge, then rinse with water.
• Pulse Charging
Pulse charging has shown that the banks do not get as sulfated as one
with the traditional 3-step charging, but will not eliminate the need for
controlled, preventive equalization.The benefit of pulse charging is that
the bank will need less overcharge and hence less maintenance.
• Battery Additives
Most battery additives are mainly a form of a common preservative,
EDTA. These additives help to increase the solubility of the sulfate in the
electrolyte (common salt effect). Some additives contain cadmium
sulfate, which could cause disposal problems in the future. These
additives are not beneficial and are not recommended.
Storage Procedure
Keep the batteries clean and always store in a cool, dry area. Where
acid is stored or handled, good ventilation is necessary. Keep the bungs
on the containers at all times.
Spillage Procedure
Small spills may be neutralized using water. Spray the spill from a
windward location wearing protective equipment. Direct the jet to the
outside of the spillage, working your way inward towards the center.
Larger spills should be contained using soda ash, sand or dirt and finally
washed down with water once absorbed.
10
Disposal Procedure
Batteries must NEVER be disposed in household waste. To reduce environmental
impacts, bring your battery to a certified recycling depot at the end of its life.
Note: Lead-acid batteries are 97-98% recyclable.
Quick Checklist
Shipping
• All parts are included
• No acid spill
• No visual damage to the batteries
Installation
• Necessary personal protective gear being worn properly
• All electrical components are turned off
• Acid spill cleanup material at hand
Initial Charge
• Verify electrolyte levels (adjust if needed)
• Measure specific gravity
• Set up battery charge voltage/current limits
General
• Safety first!
Warranty
We build one mean battery and we back them with comprehensive warranties that
lead the industry in length of coverage. We’re confident that our batteries will perform
time after time, year after year. But should a problem arise, you can be confident that
you’re covered better than any other battery warranty in the business.
Marathon, herein referred to as the Company, warrants that batteries sold by
it are merchantable and free of defects in workmanship and material at the
time they are shipped from the Company’s factory.
In the event that the Company makes a drop shipment to a distributor’s customer,
that customer must be instructed to perform an inspection of the goods BEFORE
signing the delivery slip. The Company is not responsible for damaged product
reported after shipment has been signed “Received in Good Condition”. NOTE:
ALL SHIPMENTS SHOULD BE THOROUGHLY INSPECTED FOR DAMAGE
BEFORE SIGNING THE DELIVERY SLIP. The Company will replace or,
at its option, repair any Marathon Battery sold by it that fails to conform to the
warranty stated above on a NO CHARGE BASIS as follows:
To claim a manufacturing warranty, proof of purchase must be presented,
showing the date of purchase and the battery’s serial number. The battery
must be tested by an authorized battery outlet for actual defect, and upon
confirmation of the defect, the warranty will be administered.
The Warranty does not cover shipping damage, cracked covers, cracked
cases, bulged cases from heat, freezing or explosion, discharged
batteries or the use of undersized batteries damaged from electrical
equipment. This warranty covers only manufacturing defects.
The Company makes no warranty with respect to its batteries other than the
warranty stated above. All implied warranties of merchantability and all
expressed and implied warranties of any other kind are hereby excluded.
12
SOALR Battery Warranty Claim
To receive a returned goods authorization for a Marathon battery that has
failed, we require an analysis of the battery in question. To do so, please fill
out the form below and fax it back to our technical support department. - - Once it has been established that it is a valid warranty claim, we will process
your claim for either a replacement or credit your account. With this procedure
you do not need to send the battery back unless instructed to do so by company.
FROM POS TO NEG
END OF STRING
BAT VOLTAGE** CELL
1
1
2
3
4
5
6
1
2
2
3
4
5
6
1
3
SYSTEM INFORMATION
Stand alone
Grid-Tie
Back-up
INVERTER
Make & Model
Charger Output
Absorption Voltage & Time
CHARGING SOURCE TYPE
Panels
Wind
Generator
Other
QTY
2
3
4
5
6
4
SG
BATTERY MODEL:
DATE PURCHASED:
CUSTOMER/DEALER:
1
2
3
Average daily consumption:
KWH/AC or AH/DC
Duty cycle:
Any irregular occurances?
(Lighting, component/controller failure)
4
5
6
**Open cell voltage should be taken after 2 hours rest with negative connection removed**
Date code is the four digit number located on the edge of the
cover. 1st 2 digits = Year A=1
3rd and 4th digits = month
5th to 8th digit = production sr no. of particular rating)
If low SG (Specific Gravity)
Equalize at 2.58 VPC (Voltage Per Cell). Monitor Centre Cell Tª.
OUTPUT
Marathon Battery Warranty Procedure
Please refer to product warranty for the specific model as terms and
conditions may vary.
For warranty requests and inquiries, please consult MBPL
directly or Dealer (point of purchase).
DAMAGED BATTERY
YES
Damaged batteries DO NOT qualify
for MBPL Product Warranty
NO
Check individual
cell voltages
< 2.1 VPC
Charge battery at
0.1/c20 for 10 hours
> 2.1 VPC
Check
specific
Cells
< 1.250
Charge battery at
0.1/c20 for 10 hours
gravities
All cells > 1.250
and even
All cells
> 1.250
and uneven
YES
Equalize
@ 2.58VPC
for 2 hours*
Discharge @ c/10
or c/20 rate. Contact
sales@marathonbattery.com
for assistance.
NO
NO
Holds 1.75VCP
for c/10 or
c/20 rate
Battery does NOT meet
warranty criteria. Battery is
charging and discharging
properly. Product warranty
does not apply. Please refer
to dealer for assistance.
First time
through cycle
One cell is
0.040 points lower
than others
YES
Battery meets warranty
criteria and is eligible for
repair or replacement.
Complete Maxxima Battery
warranty claim form and
mail
to MBPL Technical Support
for further instruction.
Lead Acid Battery Glossary
Absorbed (or Absorptive) Glass Mat
A technique for sealed lead-acid batteries. The electrolyte is absorbed in a
matrix of glass fibers, which holds the electrolyte next to the plate and
immobilizes it, preventing spills. AGM batteries tend to have good power
characteristics, low internal resistance, and good behavior during charging.
Amp, Ampere
Unit of electrical current. Abbreviated “A”.
Amp-hour
Unit of electrical energy, one amp of current flowing for one hour. Abbreviated Ah.
Cell
A single battery canister usually grouped together with other cells to form battery
packs of different voltages and amperages. Example: One NiCD cell is 1.20
volts; therefore, six cells packaged together makes a 7.2 volt battery pack.
Cycle
A “cycle” is a somewhat arbitrary term used to describe the process of
discharging a fully charged battery down to a particular state of
discharge. The term “deep cycle” refers to batteries in which the cycle is
from full charge to 80% discharge. A cycle for an automotive battery is
about 5%, and for telephone batteries is usually 10%.
Electrolyte
An electrically conductive medium in which current flow is due to the
movement of ions. In a lead-acid battery, the electrolyte is a solution of
sulfuric acid. In other batteries, the electrolyte may be very different.
Flooded Cell
A design for lead-acid batteries. The electrolyte is an ordinary liquid solution of
acid. Flooded cells are prone to making gas while being charged. They must be
periodically checked for fluid level and water added as necessary. Flooded cells
are also typically less expensive than AGM or gel type lead-acid batteries.
Hydrometer
A tool for testing the Specific Gravity of a fluid, such as the electrolyte in
a flooded battery. Typically, a squeeze-bulb is used to suck up a sample
of the fluid, and a float indicates the specific gravity.
Specific Gravity
The density of a material, expressed as the ratio of the mass of a given
volume of the material and the mass of the same volume of water; a
specific gravity greater than 1 means heavier than water, less than 1
means lighter than water. The specific gravity of the electrolyte in a
battery can be used to measure the state of charge of the battery.
Sulfation
Even though lead sulfate is created in the materials of plates during normal
discharging, this term is used to describe the generation of a different form (large
crystals) of lead sulfate which will not readily convert back to normal material when
the battery is charged. Sulfation occurs when a battery is stored too long in a
discharged condition, if it is never fully charged, or if electrolyte has become
abnormally low due to excessive water loss from overcharging and/or evaporation.
Volt
The unit of measurement of electrical potential or “pressure”. Most
batteries come in 12 Volt. A single cell is 2 volts.
16
Contacts
Marathon Batteries (P) Ltd
S-10 -11, Dwarika Towers
Central Spine, Vidyadhar Nagar
Jaipur. 302023 Rajasthan
North India
Board No: +91-141-2339705
Phone: +91-9214210543
sales@marathonbatteris.com
www.marathonbatteries.com